Controller, Throttle, and Harness Safety Triage

Use this guide for no throttle response, intermittent power, error codes, sparks, or damaged wiring.

This guide does not authorize opening a controller or battery.

Stop Testing Immediately If

• The motor runs without throttle input.
• Wiring or terminals become hot.
• You see sparks or arcing.
• Insulation or connectors are melted.
• You smell burning electronics.
• A battery connector is scorched.
• Bare conductors are visible.
• The wheel cannot be safely raised.
• A red fault or thermal warning appears.
• The same fault immediately returns.

Power down normally when safe. Do not reconnect the battery if a controller short circuit is suspected.

Before Touching Connectors

1. Turn the vehicle off.
2. Remove the battery when the product procedure allows it.
3. Allow stored energy to discharge as instructed.
4. Photograph connections before disconnecting anything.
5. Pull connectors by their housings, not wires.
6. Never bridge terminals with a tool.

Visual Inspection

Inspect for loose terminal screws, discolored posts, melted plastic, pinched wiring, chafed insulation, corrosion, water, bent or pushed-back pins, incomplete seating, incorrect polarity, cable tension, and modifications.

Do not clean and reuse a connector if heat damage, pitting, deformation, or exposed conductor remains.

Throttle Does Not Respond

Check the display or app for throttle, motor/M, ECU/controller, or mode-switch warnings.

Inspect the throttle cable and connector, mode switch, key switch, Hall sensor connector, and display connector.

NOTE: If using a TruMoto Controller, connect to the controller via the TruMoto App, go to troubleshooting, select THROTTLE and follow the prompts

Do not bypass or alter electrical inputs to make the vehicle run.

Intermittent Cutout

Possible causes include loose terminals, poor connector seating, voltage sag, temperature protection, damaged throttle wiring, harness movement, or incorrect configuration.

For TruMoto systems, use Ride Recording and note the exact time the fault occurs. When submitting through the TruMoto App, remain connected to and near the controller so the app can automatically include the controller information and diagnostic data.

TruMoto Controllers

• Capture screenshots of current settings and warning details.
• Use Ride Recording for intermittent faults.
• Factory-reset only when the TruMoto procedure instructs you to.
• Use only correct model-specific settings.

Never copy settings from another model.

Burnt Connector or Harness

Do not continue riding or reconnecting the system.

Submit wide and close photos of both connector sides, every controller terminal, battery and controller labels, damaged insulation, and what occurred immediately before the damage.

Repeatedly replacing a harness without identifying the cause can damage the replacement harness or controller.

What to Send Support

• Order number and bike or kit model
• Controller model, if known
• Battery voltage and mileage
• Modifications and exact symptom
• Error-code image and short video when safe
• Controller, harness, and terminal photos
• Throttle, mode-switch, Hall-sensor, and key-switch connectors
• TruMoto recording and fault timestamp when applicable

Submit a support request